[0001] This invention relates to oil-based settable spotting fluid compositions for use
in cementing wells.
[0002] Hydraulic cement compositions are commonly utilized in the construction of oil and
gas wells. For example, hydraulic cement compositions are used in primary cementing
operations whereby strings of pipe such as casings and liners are cemented in well
bores. In performing primary cementing, a hydraulic cement composition is pumped into
the annular space between the walls of a well bore and the exterior surfaces of a
pipe string disposed therein. The cement composition is permitted to set in the annular
space thereby forming an annular sheath of hardened substantially impermeable cement
therein. The cement sheath physically supports and positions the pipe string in the
well bore and bonds the exterior surfaces of the pipe string to the walls of the well
bore whereby the undesirable migration of fluids between zones or formations penetrated
by the well bore is prevented.
[0003] A variety of drilling fluids are used in drilling wells. Oil-based drilling fluids
are commonly used in applications where the permeabilities of producing formations
would be damaged if the formations were contacted by water-based drilling fluids.
However, it has heretofore been common place in the industry to use water-based settable
spotting fluids which are incompatible with the oil-based drilling fluids and often
cause well bore stability problems and damage to the permeability of producing formations.
[0004] During the drilling of a well bore, the drilling fluid used is circulated through
the drill pipe and drill bit and then upwardly through the well bore to the surface.
The drilling fluid functions to lubricate the drill bit and carry cuttings to the
surface where the cuttings and gas are removed from the drilling fluid. While drilling
fluids are not settable, i.e., they do not set into hard impermeable sealing masses
when static, drilling fluids increase in gel strength over time. Typically, after
a well bore is drilled to total depth, the drill pipe and drill bit are withdrawn
from the well bore and the drilling fluid is left in the well bore to provide hydrostatic
pressure on permeable formations penetrated by the well bore thereby preventing the
flow of formation fluids into the well bore.
[0005] The next operation in completing the well bore usually involves running a pipe string,
e.g., casing, into the well bore. Depending upon the depth of the well bore and whether
or not problems are encountered in running the pipe string therein, the drilling fluid
may remain relatively static in the well bore for a time period up to 2 weeks. During
that time, the stagnate drilling fluid progressively increases in gel strength whereby
portions of the drilling fluid in the well bore become increasingly difficult to displace.
[0006] After the pipe string has been run in the well bore, the next operation performed
is usually primary cementing. That is, the pipe string disposed in the well bore is
cemented by pumping a cement composition through the pipe string and into the annulus
between the pipe string and the walls of the well bore whereby the drilling fluid
in the annulus is displaced therefrom by the cement composition. While a variety of
techniques have been developed for improving the displacement of the drilling fluid
from the annulus, if the drilling fluid has developed gel strength due to remaining
static in the well bore for a long period of time, portions of the drilling fluid
in the well bore are bypassed by the cement composition. Since the drilling fluid
is not settable, i.e. it does not set into a rigid mass, formation fluids enter and
flow in the well bore which is highly undesirable.
[0007] Heretofore, settable spotting fluid compositions have been developed and used in
wells for various purposes including the early displacement of drilling fluids from
well bores. However, as mentioned, the settable spotting fluids have been water based
and have included blast furnace slag and other hydraulic components which slowly set
at relatively low temperatures, i.e. temperatures less than about 32°C (90°F). Also,
slag-containing settable spotting fluids are intolerant to cement composition contamination,
i.e. if well cement mixes with such spotting fluids, the spotting fluids prematurely
set. To prevent a slag-containing spotting fluid from prematurely setting, a very
strong set retarder must be added to the spotting fluid and the spotting fluid must
be separated from the cement composition by a spacer fluid. If intermixing between
the cement composition and the set retarded spotting fluid occurs, the cement composition
may be prevented from setting by the strong set retarder in the spotting fluid.
[0008] Thus, there are needs for oil-based settable spotting fluid compositions which can
be utilized in wells drilled with oil-based drilling fluids and avoid well cementing
problems of the types described above at subterranean temperatures above 32°C (90°F).
[0009] The present invention provides an oil-based settable spotting fluid for use in cementing
wells comprising: oil; an emulsifying surfactant for emulsifying said oil with water
whereby an oil-external emulsion is formed; a de-emulsifying surfactant which de-emulsifies
said oil-external emulsion when the emulsion is contacted with external water; a hydraulic
settable component selected from ASTM Class C or the equivalent fly ash and ASTM Class
F or the equivalent fly ash together with a source of calcium; and water selected
from fresh water and salt water present in an amount sufficient to form a slurry having
a density of from 1.4 x 10
3 to 1.8 x 10
3 kg/m
3 (12 to 15 pounds per gallon).
[0010] The oil-based settable spotting fluid compositions of this invention are compatible
with oil-based drilling fluids. The oil-based spotting fluids are also tolerant to
well cement contamination and as a result, the use of set retarders is not required.
Further, when displacing an oil-based settable spotting fluid composition of this
invention with a well cement composition, a spacer between the spotting fluid and
the well cement composition does not have to be utilized, and there is no need to
utilize a spacer for improving the spotting fluid displacement since any bypassed
spotting fluid will set with time.
[0011] The invention also provides a method of cementing a pipe string such as casing in
a well bore containing oil-based drilling fluid which method comprises:
(a) pumping a settable oil-based spotting fluid composition of the invention, into
said well bore to displace at least a portion of said drilling fluid out of said well
bore thereby preventing said drilling fluid from remaining in fractures or other permeable
zones in said well bore and progressively increasing in gel strength over time therein;
(b) running said pipe string to be cemented into said well bore whereby said pipe
string and well bore are at least partially filled with said settable spotting fluid;
(c) pumping and displacing said cement composition through said pipe string and into
the annulus between said pipe string and the walls of said well bore whereby said
drilling fluid and said settable spotting fluid composition in said pipe string and
said annulus are displaced therefrom except for portions of said settable spotting
fluid composition which may remain in fractures or other permeable zones therein;
and
(d) allowing said cement composition in said annulus and any settable spotting fluid
composition remaining in said fractures or other permeable zones therein to set into
hard impermeable masses therein.
[0012] The term "oil-based settable spotting fluid composition(s)" is used herein to mean
a fluid which over time will harden into an impermeable mass having sufficient compressive
strength to prevent the undesirable entry into and the flow of formation fluids in
the well bore, but which will not set for a desired relatively long period of time
in the range of from about 2 days to about 2 weeks or more. During this time, a pipe
string, e.g., casing, can be placed in the well bore and conventional cementing operations
can be completed.
[0013] The oil utilized for preparing the oil-based settable spotting fluid compositions
of this invention is preferably comprised of one or more long chain mineral oils.
A particularly suitable mixture of long chain mineral oils is commercially available
under the trade designation "ESCAID 110™" from the Exxon Corporation.
[0014] While various emulsifying surfactants for emulsifying the oil with water can be utilized,
a particularly suitable such emulsifying surfactant is alkylphenol hydroxypolyoxyethylene
which is commercially available under the trade designation "TERGITOL NP-C49™" from
Union Carbide Corporation. The emulsifying surfactant utilized is generally present
in the oil-based settable spotting fluid of this invention in an amount in the range
of from about 0.01% to about 2% by weight of water in the composition, more preferably
in the range of from about 0.01% to about 1% and most preferably in an amount of 0.05%.
[0015] The de-emulsifying surfactant which de-emulsifies the oil-external emulsion when
the emulsion is contacted with external water from the cement composition is preferably
an ethoxylated alkyl alcohol glycol ether ethoxylated with from about 3 to about 10
moles of ethylene oxide and wherein the alkyl alcohol has from about 12 to about 16
carbon atoms. Such a de-emulsifying surfactant is commercially available under the
trade designation "SURFONIC® L24-7" from Huntsman Petrochemical Co. The de-emulsifying
surfactant utilized is generally present in the oil-based settable spotting fluid
in an amount in the range of from about 0.01% to about 1% by weight of oil in the
composition, more preferably in an amount of from about 0.01% to about 0.5% and most
preferably in an amount of 0.024%.
[0016] Fly ash is produced by the forced draft combustion of powdered coal. The fly ash
which is carried by the flue gases is recovered, for example, by electrostatic precipitators.
ASTM Class C or the equivalent fly ash contains both silica and lime and when mixed
with water forms a cementitious mixture which sets into a hard impermeable mass, i.e.,
calcium silicate hydrate. ASTM Class F fly ash does not contain lime, and a source
of calcium ion is required for it to form a cementitious composition with water. Generally,
lime is mixed with Class F or the equivalent fly ash in an amount in the range of
from about 5% to about 50% by weight of the fly ash. Of the two forms of fly ash which
are commercially available, i.e., ASTM Class C or ASTM Class F, ASTM Class F together
with lime is preferred for use in accordance with the present invention. The fly ash
utilized is generally present in an amount in the range of from about 35% to about
85% by weight of oil in the composition, more preferably in an amount of from about
55% to about 65% and most preferably in an amount of about 58.33%. When ASTM Class
F fly ash is utilized, hydrated lime is preferably used therewith in a general amount
in the range of from about 5% to about 50% by weight of ASTM Class F fly ash in the
composition, more preferably in an amount from about 10% to about 20% and most preferably
in an amount of 15%.
[0017] As mentioned, the water utilized in the oil-based settable spotting fluid compositions
of this invention can be fresh water or salt water depending upon the particular density
of the composition required. The term "salt water" is used herein to mean unsaturated
salt water or saturated salt water including brines and seawater. The water is included
in the oil-based settable spotting fluid compositions in an amount sufficient to form
a slurry having a density in the range of from about 1.4 x 10
3 to about 1.8 x 10
3 kg/m
3 (about 12 to about 15 pounds per gallon).
[0018] In order to prevent foaming when the oil-external emulsion is formed with water,
a defoaming agent can optionally be included in the composition of this invention.
While various defoaming agents can be used, a preferred defoaming agent is comprised
of polypropylene glycol, particulate hydrophobic silica and a liquid diluent. Such
a defoaming agent is commercially available under the trade designation "D-AIR 3000
L™" from Halliburton Energy Services Corporation of Duncan, Oklahoma. When used, the
defoaming agent is generally present in an amount in the range of from about 0.01%
to about 0.1% by weight of water in the composition.
[0019] A particularly preferred oil-based settable spotting fluid of this invention for
use in cementing wells comprises one or more long chain mineral oils, an emulsifying
surfactant for emulsifying the oil with water whereby an oil-external emulsion is
formed comprised of alkylphenol hydroxypolyoxyethylene present in an amount in the
range of from about 0.01% to about 1% by weight of water in the composition, a de-emulsifying
surfactant which in time de-emulsifies the oil-external emulsion when the emulsion
is contacted with external water comprised of an ethoxylated alkyl alcohol glycol
ether ethoxylated with from about 3 to about 10 moles of ethylene oxide and wherein
the alkyl alcohol has from about 12 to about 16 carbon atoms, said de-emulsifying
surfactant being present in an amount in the range of from about 0.01% to about 0.5%
by weight of oil in the composition, a defoaming agent comprised of polypropylene
glycol, particulate hydrophobic silica and a liquid diluent present in an amount in
the range of from about 0.01% to about 0.1% by weight of the water in the composition,
a hydraulic settable component comprised of ASTM Class F fly ash present in an amount
in the range of from about 55% to about 65% by weight of oil in the composition, hydrated
lime present in the composition in an amount of about 5% by weight of the hydraulic
settable component in the composition and water selected from the group consisting
of fresh water and salt water present in an amount sufficient to form a slurry having
a density in the range of from about 1.4 x 10
3 to about 1.8 x 10
3 kg/m
3 (about 12 to about 15 pounds per gallon).
[0020] In accordance with the methods of the present invention, when a well bore is drilled
with an oil-based drilling fluid to total depth and before the drilling fluid in the
well bore has had a chance to gain significant gel strength, the drilling fluid is
at least partially displaced with the oil-based settable spotting fluid composition
of this invention. The oil-based drilling fluid is usually displaced by the oil-based
settable spotting fluid composition to a level above those portions of the well bore
containing fractures, vugs and other permeable areas or zones. The oil-based spotting
fluid composition does not increase in gel strength with time, and it is easily displaced
after being static in the wellbore for a long period of time, e.g. a time period up
to about two weeks. Because the oil-based drilling fluid has not had a chance to increase
in gel strength and because the drill pipe includes large diameter drill collars and
the like which cause high annular velocity, displacement of the oil-based drilling
fluid is achieved by the oil-based settable spotting fluid composition of this invention.
[0021] After the well bore is at least partially filled with the oil-based spotting fluid
composition, the pipe string to be cemented is run in the well bore. Depending on
how much of the drilling fluid has previously been displaced, and if the pipe string
is not floated into the well bore while being filled with the oil-based spotting fluid
composition, some drilling fluid will remain in the pipe string. When the well cement
composition is pumped through the pipe string into the annulus, the oil-based drilling
fluid and the oil-based spotting fluid composition in the pipe string and annulus
are displaced ahead of the well cement composition. Because the annulus contains the
oil-based spotting fluid composition, any drilling fluid entering the annulus will
not have time to increase in gel strength therein and will be readily displaced therefrom
by the well cement composition. The oil-based settable spotting fluid composition,
if any, remaining in fractures or other permeable areas or zones in the well bore
after the annulus has been filled with cement will ultimately set thereby preventing
the entry or flow of formation fluids in the annulus.
[0022] In order to further illustrate the compositions and methods of the present invention,
the following example is given.
Example
[0023] Two oil-based compositions of this invention were prepared by the following procedure.
A long chain mineral oil mixture ("ESCAID 110™" from Exxon of Houston, Texas) was
mixed with an emulsifying surfactant ("TERGITOL NP-C49™" from Union Carbide Corp.
of Danbury, Connecticut). The emulsifying surfactant was added to the oil in an amount
of 0.05% by weight of the water.
[0024] Hydrated lime was next added to fresh water in the amount given in the Table below,
and a de-foaming agent ("D-AIR 3000L™" from Halliburton Energy Services, Inc. of Duncan,
Oklahoma) was added to the water in an amount of 0.1% by weight of the water.
[0025] The oil phase and water phase were then combined and vigorously mixed to form the
oil-external emulsion. ASTM Class F fly ash was added to the emulsion in an amount
of 58.33% by weight of the oil therein, and a de-emulsifying surfactant ("SURFONIC®
L24-7" from Huntsman Petrochemical Co. of Houston, Texas) was added to the emulsion
in an amount of .024% by weight of the water therein.
[0026] The resulting oil-based settable spotting fluid compositions were tested for rheology,
gel strength, fluid loss and set time in accordance with the procedures set forth
in API Recommended Practices 1013 issued by the American Petroleum Institute of Washington,
D.C. The results of the tests are given in the Table below.
TABLE
Properties of Oil-Based Settable Spotting Fluids |
Test |
Amount of Hydrated Lime Dissolved in Water % by Weight of Water |
|
80% |
50% |
Rheology at 27°C (80°F) |
|
|
300 rpm |
252 |
235 |
200 rpm |
211 |
198 |
100 rpm |
159 |
149 |
6 rpm |
72 |
66 |
3 rpm |
65 |
59 |
|
Gel Stength at 27°C (80°F) |
|
|
10 sec |
59 |
58 |
10 min |
59 |
61 |
30 min |
67 |
71 |
|
Fluid Loss at 27°C (80°F) |
|
|
cubic centimeters |
5 |
4.5 |
|
Set Time at 66°C (150°F) |
|
|
hours |
48 |
120 |
[0027] From the above Table, it can be seen that the oil-based settable spotting fluid compositions
of this invention have excellent properties.
1. An oil-based settable spotting fluid for use in cementing wells comprising: oil; an
emulsifying surfactant for emulsifying said oil with water whereby an oil-external
emulsion is formed; a de-emulsifying surfactant which de-emulsifies said oil-external
emulsion when the emulsion is contacted with external water; a hydraulic settable
component selected from ASTM Class C or the equivalent fly ash and ASTM Class F or
the equivalent fly ash together with a source of calcium; and water selected from
fresh water and salt water present in an amount sufficient to form a slurry having
a density of from 1.4 x 103 to 1.8 x 103 kg/m3 (12 to 15 pounds per gallon).
2. A composition according to claim 1, wherein said oil is comprised of one or more long
chain mineral oils.
3. A composition according to claim 1 or 2, wherein said emulsifying surfactant is comprised
of alkylphenol hydroxypolyoxyethylene and is present in an amount of from 0.01% to
2% by weight of water in said composition.
4. A composition according to claim 1, 2 or 3, wherein said de-emulsifying surfactant
is comprised of an ethoxylated alkyl alcohol glycol ether ethoxylated with from 3
to 10 moles of ethylene oxide and wherein the alkyl alcohol has from 12 to 16 carbon
atoms, said de-emulsifying surfactant being present in an amount of from 0.01% to
1% by weight of oil in said composition.
5. A composition according to any of claims 1 to 4, wherein said hydraulic settable component
is comprised of ASTM Class F or the equivalent fly ash together with a source of calcium,
and said ASTM Class F fly ash is present in an amount of from 35% to 85% by weight
of oil in said composition.
6. A composition according to claim 5, wherein said source of calcium is hydrated lime
and is present in an amount of from 5% to 50% by weight of ASTM Class F fly ash in
said composition.
7. A composition according to any of claims 1 to 6, which further comprises a defoaming
agent for defoaming said water when it is mixed with said oil.
8. A composition according to claim 7, wherein said defoaming agent is comprised of polypropylene
glycol, particulate hydrophobic silica and a liquid diluent, and is present in an
amount of from 0.01% to 0.1% by weight of water in said composition.
9. A method of cementing a pipe string in a well bore containing oil-based drilling fluid,
which method comprises:
(a) pumping a settable oil-based spotting fluid composition as claimed in any of claims
1 to 8, into said well bore to displace at least a portion of said drilling fluid
out of said well bore thereby preventing said drilling fluid from remaining in fractures
or other permeable zones in said well bore and progressively increasing in gel strength
over time therein;
(b) running said pipe string to be cemented into said well bore whereby said pipe
string and well bore are at least partially filled with said settable spotting fluid;
(c) pumping and displacing said cement composition through said pipe string and into
the annulus between said pipe string and the walls of said well bore whereby said
drilling fluid and said settable spotting fluid composition in said pipe string and
said annulus are displaced therefrom except for portions of said settable spotting
fluid composition which may remain in fractures or other permeable zones therein;
and
(d) allowing said cement composition in said annulus and any settable spotting fluid
composition remaining in said fractures or other permeable zones therein to set into
hard impermeable masses therein.
10. A method according to claim 9, wherein said water is unsaturated salt water, preferably
seawater.